A boiler is a closed vessel where drinking water or other fluid is heated. The fluid does not always boil. (In North America, the term "furnace" is normally used if the reason is not to boil the liquid.) The warmed or vaporized liquid exits the boiler for use in various procedures or heating applications,[1][2] including drinking water heating, central heating system, boiler-based power generation, food preparation, and sanitation.
Materials
The pressure vessel of a boiler is usually manufactured from steel (or alloy steel), or historically of wrought iron. Stainless steel, of the austenitic types especially, is not found in wetted elements of boilers thanks to stress and corrosion corrosion cracking.[3] However, ferritic stainless steel is often used in superheater sections that will not come in contact with boiling water, and electrically heated stainless steel shell boilers are allowed under the European "Pressure Equipment Directive" for production of steam for sterilizers and disinfectors.[4]
[url=https://en.wikipedia.org/wiki/Boiler]https://en.wikipedia.org/wiki/Boiler[/url]
In live steam models, copper or brass is often used since it is more easily fabricated in smaller size boilers. Historically, copper was often used for fireboxes (especially for vapor locomotives), because of its better formability and higher thermal conductivity; however, in newer times, the high price of copper often makes this an uneconomic choice and cheaper substitutes (such as steel) are used instead.
For a lot of the Victorian "age of steam", the only materials used for boilermaking was the highest grade of wrought iron, with assembly by rivetting. This iron was obtained from specialist ironworks, such as at Cleator Moor (UK), mentioned for the high quality of their rolled plate and its suitability for high-reliability use in critical applications, such as high-pressure boilers. In the 20th century, design practice instead transferred towards the use of steel, which is stronger and cheaper, with welded structure, which is quicker and requires less labour. It should be noted, however, that wrought iron boilers corrode much slower than their modern-day metal counterparts, and are less vunerable to localized pitting and stress-corrosion. This makes the durability of old wrought-iron boilers much more advanced than those of welded metal boilers.
Cast iron can be utilized for the heating vessel of local drinking water heaters. Although such heaters are usually termed "boilers" in a few countries, their purpose will be to produce hot water, not steam, and so they run at low pressure and try to avoid boiling. The brittleness of cast iron makes it impractical for high-pressure steam boilers.
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Energy
The foundation of heat for a boiler is combustion of some of several fuels, such as wood, coal, oil, or gas. Electric steam boilers use level of resistance- or immersion-type heating elements. Nuclear fission is also used as a heat source for producing steam, either straight (BWR) or, generally, in specialised heat exchangers called "steam generators" (PWR). Heat recovery steam generators (HRSGs) use heat rejected from other processes such as gas turbine.
Boiler efficiency
there are two methods to gauge the boiler efficiency 1) direct method 2) indirect method
Direct method -immediate approach to boiler efficiency test is more functional or more common
boiler efficiency =Q*((Hg-Hf)/q)*(GCV *100 ) Q =Total steam flow Hg= Enthalpy of saturated steam in k cal/kg Hf =Enthalpy of feed drinking water in kcal/kg q= quantity of fuel use in kg/hr GCV =gross calorific value in kcal/kg like pet coke (8200 kcal/KG)
indirect method -to measure the boiler efficiency in indirect method, we need a following parameter like
Ultimate analysis of gasoline (H2,S2,S,C moisture constraint, ash constraint)
percentage of O2 or CO2 at flue gas
flue gas temperature at outlet
ambient temperature in deg c and humidity of air in kg/kg
GCV of gasoline in kcal/kg
ash percentage in combustible fuel
GCV of ash in kcal/kg
Configurations
Boilers can be classified into the following configurations:
Container boiler or Haycock boiler/Haystack boiler: a primitive "kettle" where a fire heats a partially filled water container from below. 18th century Haycock boilers produced and stored large amounts of very low-pressure vapor generally, often hardly above that of the atmosphere. These could burn off wood or most often, coal. Efficiency was very low.
Flued boiler with one or two large flues-an early type or forerunner of fire-tube boiler.
Diagram of a fire-tube boiler
Fire-tube boiler: Here, drinking water partially fills a boiler barrel with a small volume left above to accommodate the vapor (steam space). This is the type of boiler used in almost all steam locomotives. Heat source is in the furnace or firebox that has to be held completely surrounded by the water in order to keep up the temperatures of the heating surface below the boiling point. The furnace can be situated at one end of the fire-tube which lengthens the road of the hot gases, thus augmenting the heating surface which can be further increased by making the gases invert direction through a second parallel pipe or a bundle of multiple tubes (two-pass or return flue boiler); additionally the gases may be studied along the sides and then under the boiler through flues (3-move boiler). In case of a locomotive-type boiler, a boiler barrel expands from the firebox and the hot gases go through a lot of money of fire tubes inside the barrel which greatly escalates the heating system surface in comparison to a single pipe and further increases heat transfer. Fire-tube boilers will often have a comparatively low rate of steam creation, but high vapor storage capacity. Fire-tube boilers mostly burn solid fuels, but are readily flexible to people of the liquid or gas variety.
Diagram of a water-tube boiler.
Water-tube boiler: In this type, pipes filled with drinking water are arranged in the furnace in a genuine quantity of possible configurations. The water pipes connect large drums Often, the lower ones formulated with drinking water and the upper ones steam and drinking water; in other cases, like a mono-tube boiler, drinking water is circulated by a pump through a succession of coils. This kind generally gives high steam production rates, but less storage capacity than the above mentioned. Water tube boilers can be made to exploit any heat source and tend to be preferred in high-pressure applications since the high-pressure water/steam is included within small diameter pipes which can withstand the pressure with a thinner wall.
Flash boiler: A flash boiler is a specialized kind of water-tube boiler in which tubes are close jointly and drinking water is pumped through them. A flash boiler differs from the kind of mono-tube steam generator in which the pipe is permanently filled with water. Super fast boiler, the tube is kept so hot that the water feed is quickly flashed into steam and superheated. Flash boilers had some use in cars in the 19th century which use continued in to the early 20th century. .
1950s design vapor locomotive boiler, from a Victorian Railways J class
Fire-tube boiler with Water-tube firebox. Sometimes the two above types have been combined in the following manner: the firebox includes an set up of water pipes, called thermic siphons. The gases then go through a typical firetube boiler. Water-tube fireboxes were installed in many Hungarian locomotives,[citation needed] but have met with little success in other countries.
Sectional boiler. Inside a ensemble iron sectional boiler, sometimes called a "pork chop boiler" the water is included inside solid iron sections.[citation needed] These sections are assembled on site to produce the finished boiler.
Safety
See also: Boiler explosion
To define and secure boilers safely, some professional specialized organizations like the American Culture of Mechanical Designers (ASME) develop criteria and regulation codes. For example, the ASME Boiler and Pressure Vessel Code is a typical providing an array of guidelines and directives to ensure compliance of the boilers and other pressure vessels with security, security and design standards.[5]
Historically, boilers were a way to obtain many serious injuries and property destruction due to badly understood engineering principles. Thin and brittle metal shells can rupture, while welded or riveted seams could start poorly, resulting in a violent eruption of the pressurized steam. When water is changed into steam it expands to over 1,000 times its original volume and travels down vapor pipes at over 100 kilometres each hour. As a result of this, steam is a superb way of moving energy and temperature around a site from a central boiler house to where it is needed, but with no right boiler feed water treatment, a steam-raising seed are affected from scale corrosion and formation. At best, this increases energy costs and can lead to poor quality vapor, reduced efficiency, shorter plant life and unreliable procedure. At worst, it can lead to catastrophic failing and lack of life. Collapsed or dislodged boiler tubes can also spray scalding-hot vapor and smoke out of the air intake and firing chute, injuring the firemen who insert the coal into the open fire chamber. Extremely large boilers providing a huge selection of horsepower to operate factories could demolish entire buildings.[6]
A boiler which has a loss of feed water and is permitted to boil dry can be hugely dangerous. If give food to drinking water is sent in to the bare boiler then, the small cascade of incoming drinking water instantly boils on connection with the superheated metal shell and leads to a violent explosion that can't be managed even by safety steam valves. Draining of the boiler can also happen if a leak occurs in the vapor supply lines that is larger than the make-up water source could replace. The Hartford Loop was created in 1919 by the Hartford Vapor Boiler and Insurance Company as a strategy to help prevent this problem from happening, and thereby reduce their insurance promises.[7][8]
Superheated steam boiler
A superheated boiler on a steam locomotive.
Main article: Superheater
Most boilers produce steam to be used at saturation temperature; that is, saturated steam. Superheated vapor boilers vaporize water and then further high temperature the steam in a superheater. This provides vapor at higher heat range, but can reduce the overall thermal efficiency of the steam generating place because the bigger vapor temp takes a higher flue gas exhaust heat.[citation needed] There are several ways to circumvent this problem, by providing an economizer that heats the give food to drinking water typically, a combustion air heater in the hot flue gas exhaust path, or both. You will find advantages to superheated vapor that may, and often will, increase overall efficiency of both steam generation and its own utilization: benefits in input heat range to a turbine should outweigh any cost in additional boiler problem and expense. There may also be useful restrictions in using moist steam, as entrained condensation droplets will damage turbine blades.
Superheated steam presents unique safety concerns because, if any system component fails and allows steam to escape, the high pressure and temperature can cause serious, instantaneous injury to anyone in its path. Since the escaping steam will initially be completely superheated vapor, detection can be difficult, although the extreme heat and sound from such a leak clearly indicates its presence.
Superheater operation is similar to that of the coils on an air conditioning unit, although for a different purpose. The vapor piping is directed through the flue gas route in the boiler furnace. The temp in this area is normally between 1,300 and 1,600 °C (2,372 and 2,912 °F). Some superheaters are radiant type; that is, they absorb heat by rays. Others are convection type, absorbing heat from a liquid. Some are a mixture of both types. Through either method, the extreme heat in the flue gas path will heat the superheater steam piping and the steam within also. While the heat range of the vapor in the superheater increases, the pressure of the vapor does not and the pressure remains exactly like that of the boiler.[9] Almost all steam superheater system designs remove droplets entrained in the steam to prevent damage to the turbine blading and associated piping.
Supercritical steam generator
Boiler for a charged power flower.
Main article: Supercritical steam generator
Supercritical steam generators are frequently used for the production of energy. They operate at supercritical pressure. As opposed to a "subcritical boiler", a supercritical steam generator operates at such a high pressure (over 3,200 psi or 22 MPa) that the physical turbulence that characterizes boiling ceases to occur; the fluid is liquid nor gas but a super-critical fluid neither. There is no era of vapor bubbles within the water, because the pressure is above the critical pressure point at which steam bubbles can develop. As the liquid expands through the turbine levels, its thermodynamic condition drops below the critical point as it can work turning the turbine which turns the power generator from which power is eventually extracted. The fluid at that point may be considered a mixture of vapor and liquid droplets as it goes by into the condenser. This results in slightly less fuel use and therefore less greenhouse gas production. The word "boiler" shouldn't be used for a supercritical pressure steam generator, as no "boiling" occurs in this product.
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Accessories
Boiler fittings and accessories
Pressuretrols to regulate the vapor pressure in the boiler. Boilers generally have two or three 3 pressuretrols: a manual-reset pressuretrol, which functions as a safety by setting the upper limit of steam pressure, the operating pressuretrol, which handles when the boiler fires to maintain pressure, as well as for boilers equipped with a modulating burner, a modulating pressuretrol which controls the amount of fire.
Safety valve: It can be used to relieve pressure and stop possible explosion of a boiler.
Water level signals: They show the operator the level of fluid in the boiler, known as a sight cup also, water measure or drinking water column.
Bottom level blowdown valves: They provide a way for removing solid particulates that condense and rest on underneath of a boiler. As the name indicates, this valve is situated straight on the bottom of the boiler usually, and is sometimes opened up to use the pressure in the boiler to drive these particulates out.
Continuous blowdown valve: This enables a small quantity of water to flee continuously. Its purpose is to avoid the water in the boiler becoming saturated with dissolved salts. Saturation would lead to foaming and cause water droplets to be carried over with the steam - an ailment known as priming. Blowdown is also often used to monitor the chemistry of the boiler drinking water.
Trycock: a type of valve that is often use to manually check a water level in a container. Most found on a drinking water boiler commonly.
Flash container: High-pressure blowdown enters this vessel where the vapor can 'flash' safely and be found in a low-pressure system or be vented to atmosphere as the ambient pressure blowdown flows to drain.
Automatic blowdown/continuous heat recovery system: This technique allows the boiler to blowdown only when makeup water is flowing to the boiler, thereby transferring the utmost amount of heat possible from the blowdown to the makeup water. No flash container is generally needed as the blowdown discharged is close to the heat of the makeup water.
Hand holes: These are steel plates installed in openings in "header" to permit for inspections & installing tubes and inspection of internal surfaces.
Vapor drum internals, some display, scrubber & cans (cyclone separators).
Low-water cutoff: It is a mechanical means (usually a float switch) that can be used to turn off the burner or shut down gasoline to the boiler to avoid it from working once the water moves below a certain point. If a boiler is "dry-fired" (burnt without drinking water in it) it can cause rupture or catastrophic failure.
Surface blowdown collection: It offers a means for removing foam or other lightweight non-condensible substances that have a tendency to float together with water inside the boiler.
Circulating pump: It is designed to circulate drinking water back again to the boiler after they have expelled a few of its heat.
Feedwater check valve or clack valve: A non-return stop valve in the feedwater range. This may be fitted to the side of the boiler, just below water level, or to the very best of the boiler.[10]
Top give food to: With this design for feedwater injection, the water is fed to the top of the boiler. This may reduce boiler exhaustion triggered by thermal stress. By spraying the feedwater over a series of trays water is quickly warmed and this can reduce limescale.
Desuperheater tubes or bundles: A series of pipes or bundles of tubes in the water drum or the vapor drum made to cool superheated vapor, in order to supply auxiliary equipment that does not need, or may be damaged by, dry out vapor.
Chemical substance injection line: A connection to add chemicals for controlling feedwater pH.
Steam accessories
Main steam stop valve:
Steam traps:
Main steam stop/check valve: It is utilized on multiple boiler installations.
Combustion accessories
Energy oil system:gasoline oil heaters
Gas system:
Coal system:
Soot blower
Other essential items
Pressure gauges:
Feed pumps:
Fusible plug:
Inspectors test pressure gauge attachment:
Name dish:
Registration dish:

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